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Polymer Composite Insulators

Polymer Composite Insulators

The polymer composite insulators are used in electrical transmission and distribution systems to support and insulate high-voltage conductors. Polymer Composite Insulators are lighter in weight, have higher mechanical strength, are better resistant to pollution, have improved hydrophobicity and needs lower maintenance costs compare to conventional porcelain or glass insulators. At WSI, we take pride in being one of the upcoming polymer composite insulator manufacturers in India. With a commitment to innovation, quality, and customer satisfaction, we have established ourselves as a trusted name in the industry.

Our Diverse Applications

LONG ROD INSULATOR FOR POWER TRANSMISSION LINES 66 KV TO 765 KV

Long rod insulators for power transmission line from 66 kV up to 765 kV for both heavy and very heavy polluted site condition.

LONG ROD INSULATOR FOR POWER DISTRIBUTION LINES 11 KV TO 33 KV

Long rod insulators for power distribution line from 11 kV up to 33 kV for both heavy and very heavy polluted site condition.

LINE POST, STATION POST AND PIN INSULATOR FOR POWER DISTRIBUTION LINES 11 KV TO 33 KV

Line post, Station post and Pin insulator for power distribution line from 11 kV up to 33 kV for both heavy and very heavy polluted site condition.

WSI Polymer Composite Insulators Range

We offer a comprehensive range of transformer bushings designed to meet a wide spectrum of voltage and current requirements. WS bushings are available for voltage ratings ranging from 3.5 kV to 52 kV, with current ratings from 250 Amps to 3150 Amps. Our products adhere to both Indian standards (IS) and German standards (DIN), ensuring the highest quality and reliability.

ANSI POLYMER POST INSULATORS 95 BIL to 350 BIL
ANSI POLYMER POST INSULATORS 110 BIL to 900 BIL

Designation	Units	TB-36/250	TB-36/630	TB-36/1000	TB-36/2000	TB-36/3150
Voltage Rating	kV	36	36	36	36	36
Current Rating	Amps	250	630	1000	2000	3150
Creepage distance	mm	576 / 720	576 / 720	576 / 720	576 / 720	576 / 720
Length (TL)	mm	485	510	540	540	540
Shed Outer diameter (SD)	mm	155	180	195	225	225
Collar outer diameter (CD)	mm	111 +0 -7	128 +0 -8	163 +0 -10	183 +0 -12	183 +0 -12
Bottom groove outer diameter (GD)	mm	70	85	100	125	125
Inner diameter (ID)	mm	33 +3 -0	39 +3 -0	58 +4 -0	74 +5 -0	74 +5 -0

ANSI Reference Number	Units	TR 225	TR 231	TR 278	TR 286	TR 288	TR 304
Cantilever Strength (upright)	lbs	4000	4000	3000	1700	1400	950
Cantilever Strength (upright)	kN	17.8	17.8	13.4	7.6	6.2	4.2
Total Height (H)	inch (mm)	12 (305)	20 (508)	30 (762)	45 (1143)	54 (1372)	80 (2032)
Top Metal Part Diameter (D)	inch (mm)	5.9 (150)	5.9 (150)	5.9 (150)	5.9 (150)	5.9 (150)	5.9 (150)
Bottom Metal Part Diameter	inch (mm)	5.9 (150)	5.9 (150)	5.9 (150)	5.9 (150)	5.9 (150)	5.9 (150)
Top Pitch Circle Diameter	inch (mm)	5 (127)	5 (127)	5 (127)	5 (127)	5 (127)	5 (127)
Number of Holes and Hole dia.	-	4 x 5/8"	4 x 5/8"	4 x 5/8"	4 x 5/8"	4 x 5/8"	4 x 5/8"
Bottom Pitch Circle Diameter	inch (mm)	5 (127)	5 (127)	5 (127)	5 (127)	5 (127)	5 (127)
Number of Holes and Hole dia.	-	4 x 5/8"	4 x 5/8"	4 x 5/8"	4 x 5/8"	4 x 5/8"	4 x 5/8"
Total Creepage Distance	inch (mm)	15.5 (394)	37 (940)	60 (1524)	99 (2515)	116 (2946)	165 (4191)
Dry Power Frequency Withstand Voltage	kV	50	90	155	245	290	405
Wet Power Frequency Withstand Voltage	kV	45	80	145	230	275	385
Impulse Withstand Voltage Positive	kVp	110	200	350	550	650	900
Impulse Withstand Voltage Negative	kVp	110	200	350	550	650	900
Impulse Flashover Voltage Positive	kVp	125	225	390	610	710	1010
Impulse Flashover Voltage Negative	kVp	130	235	405	630	730	1030
RIV Test Voltage	kV	10	22	44	73	88	146
Maximum RIV	?V	50	100	200	200	200	500
Cantilever Strength (upright)	lbs	4000	4000	3000	1700	1400	950
Tensile Strength	lbs	16000	16000	17500	17500	17500	17500
Compression Strength	lbs	16000	16000	17500	17500	17500	17500

Key Features

WSI has developed and tested polymer composite insulators for both suspension and tension mode from 66 kV to 765 kV. The prototype sample insulator has successfully passed the 5000 hours multi-stress weather ageing test as per IEC standards at KEMA, Netherlands.

WSI is driven by the ambition to meet the ever-changing market requirements and customer expectations. WSI intends to extend its product range in the field of Polymer Composite Insulators by developing:

Composite Polymer Solidcore Post Insulators for station post applications up to 400 kV.
Composite Polymer Hollow Core Insulator for Gas insulated Switchgear (GIS) and other applications up to 400 kV.

WS is committed to providing innovative products and services that meet the highest quality standards and ensure the safety and reliability of the power systems. WS aims to promote the cause of energy saving and environmental protection in the times to come.

Expertise at Every Step:

Our dedicated team of technical and process experts diligently oversees the manufacturing process to uphold the highest standards of quality.

Versatile Mechanical Strength Ratings:

WS Polymer Long Rod Insulator line spans a mechanical load rating range from 45 kN to 210 kN, accommodating various voltage and load requirements.

State-of-the-Art Machinery:

WS has invested in modern machinery for making FRP rod and moulding of silicone rubber housing. This ensures precision and consistency at every stage of production. FRP rod is the core component of composite polymer insulators, which provides the mechanical strength and electrical insulation. Silicone rubber housing is the outer layer of composite polymer insulators, which protects the FRP rod from environmental factors and provides the hydrophobicity and pollution resistance. By using advanced technology and equipment, WS can produce high-quality FRP rod and silicone rubber housing that meet the specifications and standards of the customers and the industry.

Stringent Quality Assurance:

Each polymer composite insulator that leaves WS factory undergoes a comprehensive quality check, covering raw material inspection, final testing, and quality inspection. We adhere to international standards (IEC) and customer specifications to guarantee the reliability and performance of WS products.